History of Power Supply for Sibu Island Resort

Generator set history Updated January 2012. ________________________________________Page 1 of 10

Gen Set History

Engineering Department of Sibu Island Resort Mersing, Johor

Prepared by Mohd Nazim / Khairul Asra

POWER supply for Sibu Island Resort (SIR) is from generator set located at power house behind the main office building, consisted of 4 units generator sets cater for energy consumption approximately in total of 1300 Amps Total Connected Load (TCL). Main office building is the main consume power that core purpose of it is administration, operation, restaurant, kitchen, meeting rooms, prayer room and etc. Individual chalet that supply by feeder pillar, approximately 10 nos. main feeder pillars for 121 units of chalets. Continues operation of Sewerage Treatment Plant and twelve hours operation of Reverse Osmosis Water Treatment plant with pump house with the pump capacity. Others will be swimming pool and accessories related to small consumption of it.

Based on 66% connected load, Sibu Island Resort required at least two running generator set to be on time

without fail to run in the events. Another one unit to be run for the load above and/or nearly 85% an another unit standby for any emergency said, i.e. failure to operated under extreme conditions.

There are four majors players in power distribution system consumed where air conditioning is the highest power consumable of 566 amps while load is running 66%, continue with water heater of total 618.68 amps, RO treatment plant pumps and others pump consumed about 628.32 amp; and lighting alone 110.48 amps.


No. 1 No.2 No.3 No.4

2010 2006 2005 2008

Cat

erp

illar

G

ene

rato

r S

et

410k

Va

Ive

co G

ene

rato

r S

et

400k

Va

Deu

tz G

ener

ato

r S

et 5

00kV

a

Deu

tz G

ener

ato

r S

et 4

00kV

a

Layout of generator set inside Generator Plant Room

Diesel storage tanks.

Synchronizing PanelBoard for generator sets


Main Switch Board rated of 2500Amp.


Generator set No. 1

Sales Model: C15 DITA Combustion: DI Aspr: TA / Engine Power: 376.0 KW 328 W/F EKW 344 W/O F / EKW Speed: 1,500 RPM After Cooler: ATAAC / Manifold Type: DRY Governor Type: LEC After Cooler Temp(C): 49 / Turbo Quantity: 1 Engine App: GP Turbo Arrangement:Hertz: 50 / Application Type: PACKAGE-DIE / Engine Rating: PGS Strategy: Low BSFC Strategy / Rating Type: PRIME Certification: N-C - 1970 – 2100


No Date Description Amounted By

1 Purchase of New Generator set c/w new 2500A Main Switch Board

SDI

2 21/4/2011

Cat engine can’t synchronizing for long hours with others gen set (Deutz 3 & 4). SDI staff come in and change avr card, also find tuning the synchronizing system until done

0.00 SDI

3 28/6/2011

Suspect engine moving from ground base due to connection between manifold and exhaust miss alignment. Contractor SDI come and fix mounting base and exhaust connection.

0.00 SDI

4 09-06-11

Turbo charger and manifold turning to red when generate power more than 200 KW. ( 1unit injector no 4 worn out ) SDI change new unit, under warranty.

0.00 SDI

5 26/9/2011Battery not charging voltage present 17vdc (normal 27vdc). Screw tensioning belt missing. Fix back function good.

0.00 SDI

6 26/9/2011Flexible piping crack and tear off. SDI come and change new unit. Under warranty.

0.00 SDI

Generator Set No.2

IVECO / ECO40-2S / Model : IVECO CURSOR / 13-TE3/Meccalte (400 KVA) / Engine Serial no. : 47244Alternator serial no. : 1192066 / No of cylinder : 6, in line / Bore x stroke : 135 X 150 mm / Total displacement : 12,880 cm3 / Air system : supercharged after cooled / Injection type : EUI (PDE), / electronically managed / Dry weight. :



1 25/9/2007Out of order due to auxiliary winding open circuit and main rotor winding mongered grounded

2 25/1/2008Sent out alternator ECO-2s for repair at Hattan Engineering

0.00 HATTAN

3 26/1/2008Received new alternator, replacement from faulty unit

0.00 HATTAN

4 27/1/2008Fix back alternator, and running back on normal condition

0.00 HATTAN

5 17/4/2009Eveco gen-set no.2 engine hunting when Syncronise with gen-set no.4. at 8.30 pm.

6 18/4/2009Eveco gen-set no 2 trip-off MCCB when With single unit at 9.30 am

7 18/4/2009Pan-Sar to re-program the ECU engine data Gen-set no. 4 deutz 400 kva to suit gen-set No. 2 control system.

0.00 PANSAR

8 05-03-09Gen set no. 2 Eveco overload trip at 7.20 Carrying load 320 kw.

0.00

9 02-09-10

Certified value of work 97.55% by BK Teo on generator set. Base on Original Contract of Supply, Repair, Overhaul and Trade-in of Diesel Generators.

319,330.00 HATAN

10 16/4/2010

Supply, install and repair radiator top reseviour tank, radiator water hose, genset running smooth, however founded another leaks near to flywheel oil sump (this will f/up with another quot).

0.00 HATAN

11 18/5/2010Founded alternator malfunction (Code 51-P), Raise PR2501

0.00 RECORD

12 28/11/2010Raise PR2447: To supply new high pressure prime power radiator.

3,650.00 K.TINGGI

13 01-05-11 Engine Inspection report, engine fail to crank. 0.00 NYLINKRecorded 3,650.00

1040 kg / Date Purchased: December 2006

Generator Set No.3

DEUTZ TPD500 / Model : TPD500 (500 KVA) / Engine Model : BF8M1015CP / Aspiration system : Turbocharged & after cooled / Starting system : Electric system / Cylinder nos / configuration : 8 Cylinder / Displacement : 19.0 / Date Purchase : April 1, 2005 / Total price : RM 187,000.00


No Date Description Amounted By1 19/10/2007 Two wyre AVR burn 0.00 RECORD2 30/1/2008 Top Overhaul by Hattan Engineering HATTAN

3 04-09-09

Deutz 500kva generator trip at 9.45am carry out 180 Kilowatt because of earth fault relay activated there is leakage current of 0.2 Amp detected fluctuated to 0.5 amps setting for tripping the power supply. (R.O) plant not running at this time.

0.00 RECORD

4 04-11-09

Deutz Generator 500kva carry out 270 kilowatt Power usage synchronizing with Iveco generator at 8.35am. When power surge to high amp there is an earth leakage 0.2 fluctuated to 0.5 amp cause of Tripping. (R.O plant Running)

0.00 RECORD

5 15/4/2009Inv:43018759 / Service & repair duetz controlling wiring and replacement filter

1,690.00 PANSAR

6 18/4/2009

Deutz Generator 500kva single running carry out 260 kilowatt power usage at 6.45pm, after check and rectify the earth leakage by Pan Sarawak the Generator still trip after 2 hour running. The problem Still can’t be solved

PANSAR

7 25/4/2009Deutz Generator 500 kva earth fault trip carrying Load 300kw. At 9.26am

0.00 RECORD

8 05-01-09

Pansar replace new protection CTs,move neutral wire From gen-set no 4 to gen-set no 3 after CT position. After that check the leakage current fall to zero and Test run for 1hour,found the gen-set running in good Operating condition.

PANSAR

9 26/11/2009 Major Service been carried? 109,000.00 PANSAR

10 15/12/2009Top Overhaul Radiator / Fuel Injector & Head / Fuel Injector Pump

48,300.00 PANSAR


11 02-02-10Labour & parts to service radiator coil, mounting & fuel pump

8,096.00 PANSAR

12 28/4/2010Founded exhaust manifold & exhaust charger getting red while load is running

0.00 RECORD

13 05-01-10 Radiator head cap blow off ehile running 0.00 RECORD14 17/5/2010 PANSAR came to verify the engine. 0.00 PANSAR

15 23/6/2010Repaired forced draft fan, narrow v-belt, filler cap

15,450.00 PANSAR

16 08-06-10

Pansar came continue repair as previous record, genertor canbot be start, however still fail, reason of fuel pump need to claibrate and service

0.00 PANSAR

17 09-09-10Install fuel injector pump after overhaul, drive shaft, completed with started the engine, running ok.

10,430.00 PANSAR

18 28/11/2010RPM tacho meter malfunction (Raise PR2448 record)

0.00 RECORD

19 01-10-11Record of genset continuously having oil leaks from the top of engine.

0.00 RECORD

20 21/1/2011Raise PR0691: High pressure injector pipe for cylinder A1.

0.00 RECORD

21 31/1/2011Inspection and repair high pressure injector pipe for cylinder A1 and B4.

910.00 NYLINK

22 02-02-11Continued repair leaking on high pressure pipe line

0.00 NYLINK

23 24/3/2011Repair High Pressure pipe line, high temp pressure O-ring/seal & testing & comissioning

5,371.00 NYLINK

24 19/4/2011Computer analysis and inspections been carried

0.00 PANSAR

25 23/6/2011Change head valve cover seal, battery alternator, V belt & L type radiator hose.

26 19/7/2011Battery alternator malfunction: Quot received by Nylink

565.00 NYLINK

Recorded 199,812.00

Generator Set No.4

DEUTZ TPD400 / TYPE:MECCALTE ECO 40-1s/4 / KVA:400,HERZ:50 / RPM:1500, 3 PHASE / VOLT: 415, AMP: 550 / Date Purchase: 2008

Other records.



1 15/12/2008Supply new generator set c/w accessories Inv:43018152 RM437800

437,800.00 PANSAR

2 18/4/2009 Setting ECU engine data 400kVA Deutz.

3 28/4/2010Founded exhaust manifold & exhaust charger getting red while load is running

0.00 RECORD

4 28/4/2010 IDMT setting not stable 0.00 RECORD

5 05-01-10Cylinder head gasket leaks, oils drip into exhaust manifold

0.00 RECORD

6 05-05-10Repaired head gasket leaks, top cover, lower gasket, exhaust manifold gasket, inlet manifold gasket

8,750.00 PANSAR

7 05-06-10Repair alternator main stator coil & synchronizing panel wiring

3,000.00 PANSAR

8 05-08-10 Carried load test after servicing been done 0.00 RECORD

9 17/5/2010PANSAR came to verify the engine. And do top overhaul

0.00 PANSAR

10 07-08-10 Labour & parts to perform top overhaul 7,000.00 PANSAR

11 19/4/2011Computer analysis and inspections been carried

PANSAR

12 25/6/2011 UVR 6 card short, Change 1 unit UVR card. 0.00 RECORD

13 19/7/2011AVR Card & T18 rotating diode not functioning - Received quot from NYLink.

2,500.00 NYLINK

Recorded 21,250.00



1 14/4/2009Supply 1 no. T18 rotating diode RM3350 (Inv:43018757)

3,350.00 PANSAR

2 02-11-09Repair Perkins 400kVa genset & supply diesel fuel tank

22,000.00 PANSAR

3 05-06-10Supply, install & calibration of oil dashpot MCCB

10,300.00 PANSAR

Recorded 35,650.00

- End of Report -

Documents

History of Power Supply for Sibu Island Resort